Process of manufacturing smokeless tobacco articles and smokeless tobacco article for oral consumption

ABSTRACT

In a process of manufacturing smokeless tobacco articles on a rod-making device, an endless tobacco web ( 1   a ), the filler web, is shaped into an endless rod ( 1   b ), preferably by use of a funnel-like formatting device ( 4 ). Another endless web ( 5   a ), the wrapper web, is provided as a wrapper and wrapped around the endless rod ( 1   b ). The endless wrapped rod is cut into individual cylindrical portions ( 11 ).

The invention relates to a process of manufacturing smokeless tobaccoarticles and a corresponding smokeless tobacco article for oralconsumption.

Manufactured smokeless tobacco is traditionally consumed in the UnitedStates and Northern Europe. Products like moist snuff or snus compriseground tobacco which can be consumed as a moist powder or as a wrappedportion (pouch) suitable to be placed between gums and cheek.

Another form of smokeless tobacco is chewing tobacco. Typical forms usedin America are Loose Leaf, Moist Plug or Twist Rolls. Plugs and Rollsare of a large size so that an appropriate portion has to be bitten off.Another type of products for chewing, so-called “Twists” or “MiniRolls”, is pre-portioned to the appropriate size and weight. This typeis especially popular in the Scandinavian countries. It has acylindrical shape, a diameter of approximately 5 mm and a length ofabout 10 mm. To manufacture such products, leaf tobacco is spun into anendless strand which is then cut into portions and treated with casings.The spinning process itself is performed manually, resulting in lowproduction volumes and high costs. Furthermore, the use of singletobacco leaves makes the product prone to large variations as tobaccoleaves can differ widely in their individual composition and tastecharacteristics.

The current process of producing chewing tobacco portions is describedin “An old craft for a new era” by House of Oliver Twist A/S, Denmark,ISBN 87-990650-0-2, pp 37-38. Its core process step is the manualspinning of tobacco leaves into an endless strand. It is said that“Technology cannot replace the steady skill of a spinner” (ibid.).

EP 0 483 931 A1 describes a mechanical process of manufacturing chewingtobacco by winding at least one tobacco wrapper tightly and helicallyaround a mandrel. It is neither disclosed, however, which kind oftobacco wrapper is to be used for this process nor is there any detaileddescription of the technical implementation of the process. Anotherdisadvantage is that this process requires additional handling forcutting single rods into smaller pieces.

Manufacturing of paper filters for filter cigarettes on a rod maker likethe Hauni® KDF-2 or the Decoufle® CU-20 rod-making device is state ofthe art in the tobacco industry (see, e.g., U.S. Pat. No. 5,074,320 orU.S. Pat. No. 5,709,227).

The object of the invention is to provide smokeless tobacco articles ina more economic way and in a more homogeneous quality, compared to thesmokeless tobacco articles produced by the state-of-the-art methodsindicated above.

This object is achieved by a process of manufacturing smokeless lesstobacco articles having the features of claim 1 and by a smokelesstobacco article for oral consumption having the features of claim 23.Claim 20 is directed to the use of a tobacco article manufacturedaccording to the above process as a smokeless tobacco article.Advantageous versions of the invention follow from the dependent claims.

In the invention, it was found that a process similar to the process ofmanufacturing paper filters on a rod maker as mentioned above isperfectly suited to manufacture tobacco-containing portions as requiredfor chewing tobacco or other smokeless tobacco products. By using arod-making device, an endless tobacco web (filler web) is shaped into anendless strand or rod, which, after wrapping, is cut into pieces (in thefollowing called “cylindrical portions”, although their shape can bedifferent from that of a cylinder, e.g., somewhat irregular). Thisprocess is fast and economic. Providing the filler tobacco material bymeans of an endless tobacco web results in a very homogeneous product,in particular when the tobacco web comprises reconstituted tobacco.Moreover, modern casing application methods can be used in order toapply additives for adjusting the properties of the filler material.

The wrapped tobacco portions obtained in this way can be furtherprocessed in several ways. For example, a second wrapper can be applied,e.g., after cutting the endless rod into cylindrical portions but alsoduring the application of the first wrapper, and the second wrapper canbe sealed. In this way, e.g. cushion-shaped tobacco portions which arewrapped in water-permeable materials and resemble pouched snus or moistsnuff (as currently marketed, e.g. in Sweden or in U.S.A.) can bemanufactured.

More details of the invention follow from the disclosure in the claimsand from the examples and embodiments presented in the followingdetailed description. The drawings show in

FIG. 1 a schematic representation of an embodiment of the process ofmanufacturing smokeless tobacco articles according to the invention,

FIG. 2 a schematic representation of an embodiment for furtherprocessing single cylindrical portions, and

FIG. 3 a schematic representation of another embodiment for furtherprocessing single cylindrical portions.

In the process illustrated in FIG. 1, a tobacco web 1 a (filler web) isfed from a bobbin through an optional embossing unit 2. A casing isapplied to the web 1 a by spraying an additive onto the web 1 a in aspraying unit 3 or by any other suitable process, e.g. by sizing. Theweb 1 a is then led through a funnel-shaped device 4 where it isstochastically folded into a round strand 1 b. Wrapping material 5 a isfed from a second bobbin and a glue track 7 can be applied onto thewrapping material 5 a by means of a nozzle 6. An additional wrappingmaterial 5 b can be optionally applied together with the first wrappingmaterial 5 a. Preferably, the second wrapping material 5 b (forming theouter layer of the wrapped rod) has a larger width than the firstwrapping material 5 a. A suitable format unit 8 is used to wrap thewrapping material 5 a (or 5 a and 5 b) around the tobacco materialstrand. A heating zone 9 can be used to facilitate the gluing of theseam of the wrapper material. The endless wrapped rod is then cut intocylindrical portions 11 by cutting means 10.

In one embodiment of the invention, the cylindrical portions 11 areready to be packed and marketed.

Another embodiment of the invention is illustrated in FIG. 2, whichshows how cylindrical portions 11 obtained by using the set-up of FIG. 1can be further processed. The cylindrical portions 11 are pressedbetween cylindrical stamps 20 having a diameter that is slightly smallerthan that of the wrapper of the cylindrical portions. By doing so, voidspaces 21 are formed on both sides of the cylindrical portions (stepsi), ii), iii)). By applying a suitable glue, which might also beincorporated into the wrapping material, e.g., as a hot-melt glue likePolyethylene, and by pressing the end areas (at 22) of the wrapper inthe region of the void spaces 21, a cushion-like product 23 is formedwhich is completely encapsulated in the wrapping material (step iv). Ifa flat shape is to be obtained, this can be achieved by pressing theproduct 23 as shown in step v).

A further embodiment of the invention is illustrated in FIG. 3.Cylindrical portions 11, as obtained, e.g. by using the set-up of FIG.1, are pressed by suitable means 30 to bring them into a cylindricalshape 31 having an elliptic cross-section (steps i), ii)). A secondwrapper 32 is placed over a respective portion 31 in a way that itprotrudes with respect to the portion 31 on both ends (step iii)). Theprotruding ends of the second wrapper 32 are then sealed at 33 (step iv)to provide a cushion-shaped product 34, which is completely encapsulatedin the second wrapping material 32 (step v)). It is evident that thepressing of step i) might also be carried out at a different point ofthe process, e.g. in combination with step iv).

Tobacco webs that are suitable for the inventive process can be obtainedby tobacco reconstitution processes which are familiar to those skilledin the art, e.g. the paper-type or slurry-type process. Usable for theprocess are also cellulose materials that are coated with a tobaccoslurry. Typically, such webs have a thickness between 0.05 and 0.5 mm.Preferably, the width of the tobacco web is in a range of 100 to 1000mm, depending on the thickness and the diameter of the rod to be formed.

As common in the process of manufacturing paper filters, the tobacco webmight also be embossed or corrugated with a suitable set of rollers,e.g., as used in the commercially available CUB-400 device (BurghartTabaktechnik, Hamburg, Germany).

To add specific taste characteristics, casing materials can be appliedto the tobacco web prior to rod formation (see FIG. 1, at 3).Conventional spraying nozzles might be used to apply a liquid casingonto the upper and/or lower side of the web. Other methods comprise theuse of rotating discs (as used in the SUB-01 spraying unit of BurghartTabaktechnik, Hamburg, Germany) or size press techniques.

To obtain the required moisture content of the finished product, the useof aqueous casings is preferred. These casings may contain tastefulcomponents known to those skilled in the art as liquorice, cocoa orflavours. Polyoles and sugars can be applied to add sweetness but alsoto act as humectants.

Other possible constituents comprise sweeteners, preservatives, glues,dyes, emulsifiers or thickeners.

Usable wrapping materials comprise tobacco webs of the types describedabove, preferably if the cylindrical portions are not intended to beprocessed further. Another possibility is the use of a water permeablefleece made from cellulose or modified cellulose, e.g. viscose. Thistype of material is preferred as the outer material for cases in whichthe portions are completely encapsulated. A further possibility is theuse of a water-soluble film as wrapping material, preferably as thefirst wrapper if the product is subject to a second wrapping process asdescribed above.

For sticking the seam of the wrapper as well as for adhering the openends in an optional follow-up process, different gluing methods can beused. Water-based starch or PVA glues might be applied, preferablyfollowed by a subsequent heating of the seam. It is also possible to usea hot-melt glue which is usually applied through a heated nozzle. Incase of a water-permeable cellulosic web to be used as the outerwrapper, thermoplastic fibres such as polyethylene or latex binders canbe incorporated into the web during its manufacture, allowing toaccomplish sealing by simply applying heat and pressing.

Thus, a manifold of different products can be obtained by the inventiveprocess. Without limiting the scope of the invention, some of these arefurther described in the following examples:

EXAMPLE 1

A paper-type reconstituted tobacco web with a width of 250 mm was fedfrom a bobbin through a spraying chamber where 40% wt/wt of an aqueouscasing were applied to it. The sprayed web was then fed into a Hauni®KDF-1 rod-making machine equipped with a funnel-shaped entry zone andsuitable format parts to obtain a rod diameter of 6.4 mm. The rod waswrapped with a second paper-type reconstituted tobacco web having awidth of 22 mm. The seam was sealed by applying a water-based PVA glueand subsequent heating. The rod was cut into portions of 10 mm length.

The finished product was evaluated by an expert panel and was regardedto be acceptable with regard to taste and physical stability when usedas chewing tobacco.

EXAMPLE 2

The same material and equipment as for Example 1 were used. Beforeapplication of the casing, the tobacco web was treated in an embossingunit consisting of two rolls. No difference was found with regard tofinal product characteristics.

EXAMPLE 3

A slurry-type reconstituted tobacco web with a width of 300 mm was fedfrom a bobbin through a spraying unit where 3% (by weight) of water wasapplied. A rod of 8.0 mm diameter was formed using the same equipment asin Example 1. The rod was simultaneously wrapped with two layers, anedible film of 25 mm width as the inner layer and a porous viscose webwith incorporated polyethylene fibres having a width of 27 mm as theouter layer. The seam of the outer layer was sealed by applyingsufficient heat for the polyethylene to melt. The rod was cut intocylindrical portions of 20 mm length. These portions were then fed intoa press with stamps of 7.5 mm diameter, where the axial ends of theportions were pressed to obtain a void space of approx. 4 mm on each endof the portion. Heated bars were then used to press and seal the ends.In this way, a cushion-like smokeless tobacco product with adouble-layer wrap was obtained.

1. Process of manufacturing smokeless tobacco articles on a rod-makingdevice, comprising the steps of: shaping an endless tobacco web, thefiller web, into an endless rod, preferably by use of a funnel-likeformatting device, providing another endless web, the wrapper web, as awrapper and wrapping the endless rod with that wrapper, cutting theendless wrapped rod into single cylindrical portions.
 2. Processaccording to claim 1, characterized in that the filler web is providedin one of the following basic forms: paper-type reconstituted tobaccoweb, slurry-type reconstituted tobacco web, cellulosic web coated with atobacco material.
 3. Process according to claim 1, characterized in thatthe seam of the wrapper wrapped around the endless rod is glued beforeperforming the cutting step.
 4. Process according to claim 1,characterized in that additives are applied to the filler web beforeperforming the shaping step.
 5. Process according to claim 4,characterized in that the additives are applied as an aqueous solutionor emulsion by sizing or spraying.
 6. Process according to claim 4,characterized in that the additives comprise at least one substanceselected from the substances included in the following list: water,polyols, humectants, sugars, sweeteners, preservatives, salts, acids,taste enhancers, cocoa and cocoa products, liquorice and liquoriceproducts, thickeners, starches, emulsifiers, fibres, artificial andnatural flavours, colouring agents and dyes, whiteners, glues. 7.Process according to claim 1, characterized in that the filler web has athickness in the range of from 0.05 mm to 0.5 mm and a width in therange of from 100 mm to 1000 mm.
 8. Process according to claim 1,characterized in that the wrapper web has a thickness in the range offrom 0.05 mm to 0.5 mm and a width in the range of from 15 mm to 50 mm.9. Process according to claim 1, characterized in that a second wrapperweb is provided which is applied before performing the cutting step, thesecond wrapper web preferably being wrapped simultaneously with thewrapper web.
 10. Process according to claim 9, characterized in that thesecond wrapper web has a larger width than the wrapper web.
 11. Processaccording to claim 1, characterized in that, after performing thecutting step, the respective cylindrical portions are provided with anouter wrapper.
 12. Process according to claim 11, characterized in thatthe outer wrapper is supplied from an endless hose that is cut to lengthafter accommodating respective cylindrical portion, the outer wrapperpreferably having a larger length than the cylindrical portion. 13.Process according to claim 11, characterized in that the outer wrapperis supplied from a web that is wrapped around a respective cylindricalportion and cut to length, the outer wrapper preferably having a largerlength than the cylindrical portion.
 14. Process according to claim 11,characterized in that the outer wrapper contains a glue, preferably ahot-melt glue.
 15. Process according to claim 11, characterized in thatthe outer wrapper containing a respective cylindrical portion is sealedto form a single portion, preferably the outer wrapper having a largerlength than the cylindrical portion and being sealed at both ends. 16.Process according to claim 1, characterized in that, after performingthe cutting step, the tobacco in the respective cylindrical portions ispressed in axial direction from both ends to form void spaces inside thewrapper in both end regions of a respective cylindrical portion. 17.Process according to claim 16, characterized in that, after formation ofthe void spaces, the wrapper in both end regions of a respectivecylindrical portion is pressed and sealed to form an article that isclosed on both axial ends.
 18. Process according to claim 1,characterized in that a respective generally cylindrical article formedso far is pressed into an elliptic cylindrical shape or a cushion-likeshape.
 19. Process according to claim 1, characterized in that arespective tobacco article has a length in the range of from 5 mm to 40mm, preferably in the range of from 8 mm to 20 mm.
 20. Use of a tobaccoarticle manufactured according to claim 1 as a smokeless tobaccoarticle.
 21. Use according to claim 20, characterized in that thetobacco article is a chewing tobacco article.
 22. Use according to claim21, characterized in that the chewing tobacco article is a singlechewing tobacco portion.
 23. Smokeless tobacco article for oralconsumption, preferably chewing, manufactured by the process defined inclaim 1, comprising: an inner portion comprising a multiple-foldedtobacco web material as filler material and one or more wrapping layers.24. Smokeless tobacco article according to claim 23, characterized inthat the filler material comprises one of the following materials:paper-type reconstituted tobacco, slurry-type reconstituted tobacco,cellulosic web material coated with a tobacco material.
 25. Smokelesstobacco article according to claim 23, characterized in that the fillermaterial contains additives comprising at least one substance selectedfrom the substances included in the following list: water, polyols,humectants, sugars, sweeteners, preservatives, salts, acids, tasteenhancers, cocoa and cocoa products, liquorice and liquorice products,thickeners, starches, emulsifiers, fibres, artificial and naturalflavours, colouring agents and dyes, whiteners and glues.
 26. Smokelesstobacco article according to claim 23, characterized in that at leastone of the wrapping layers is made of one of the materials selected fromthe following list: paper-type reconstituted tobacco, slurry-typereconstituted tobacco, cellulosic web material coated with a tobaccomaterial, water-permeable fleece material made of cellulose or modifiedcellulose, water-dissolvable film.
 27. Smokeless tobacco articleaccording to claim 23, characterized by a generally cylindrical shapewith both axial ends being left unwrapped.
 28. Smokeless tobacco articleaccording to claim 27, characterized by a diameter in the range of from4 mm to 20 mm, preferentially of from 5 mm to 12 mm.
 29. Smokelesstobacco article according to claim 23, characterized by a cushion-likeshape and being completely enclosed by at least one of the wrappinglayers.
 30. Smokeless tobacco article according to claim 29,characterized by a width and a height in the range of from 3 mm to 25mm, preferentially of from 5 mm to 15 mm.
 31. Smokeless tobacco articleaccording to claim 23, characterized by a length in the range of from 5mm to 40 mm, preferably in the range of from 8 mm to 20 mm. 32.Smokeless tobacco article according to claim 23, characterized in thatthe tobacco content is higher than 50%, preferably higher than 75%,related to dry weight.
 33. Smokeless tobacco article according to claim23, characterized by a nicotine content of from 0.3% to 3.5%, preferablyof from 0.5% to 2.0%, related to dry weight.